WP advice

[Brian VT]

I have an '03 EC300 with WP front, .42 springs, and the previous owner changed the stack to something recommended by a shop in upstate NY. I like it fine but that may be because I don't know any better. I'm 160 lbs. + gear and backpack.
I'm sending my forks in for regular maintenance. I have a set of .40 springs. What effect would I notice from changing springs ? How about if I changed from 5 wt. oil to 2 1/2 wt. ?
I'm a slow C enduro rider and can use all the help I can get for nasty rocks and roots in tight trails that are often muddy.

[GMP]

Brian,

I would say the .40s may be better for the rocks. I'm a bit heavier and a B rider and I ran the .42s. If you can, send the forks to Les. He will do more than swap shims and you will like it. The midvalve/checkplate shims in that fork take a beating and need regular replacement or you can loose rebound control.

[Brian VT]

Thanks for the confirmation on the springs.
I'd like to send them to Les and see if his magic works for me.
I'm just afraid of what the end cost might be and then possibly not even noticing much difference, since I'm just a wannabe.
I'm thinking I'll just have the local guy freshen them up, replace what's worn, and put the .40s in.
I guess I won't know if they can be better, but they seem pretty good to me. They're much better than my XR650R.

[Brian VT]

It was suggested that I do them myself and, since we just got 4" of snow and my next race isn't for a while, I think I will try it. I'm sure the 1st time sucks but I might learn to enjoy it as I do some other bike chores.
A little help to start, please:
-Pivot Works doesn't list a fork kit for GG.
KTM EXC300 2000-2001 = PWFFK-T01-531
KTM EXC300 2002 = PWFFK-T03-531
KTM EXC300 2003-2005 = PWFFK-T04-531
All the same ? Which for my '03 Gasser with 43mm WP ?
-What are the signs that other parts need replacing (shims, etc.)?
-Thoughts on going from 5 wt. to 2 1/2 wt. oil ?
-Tools that are worth buying instead of improvising ?

[Dave]

Pivot Works doesn't list a fork kit for GG.
KTM EXC300 2000-2001 = PWFFK-T01-531
KTM EXC300 2002 = PWFFK-T03-531
KTM EXC300 2003-2005 = PWFFK-T04-531

Get the earlier EXC kit for your 43s - the later kit is for 48mm tubes.

What are the signs that other parts need replacing (shims, etc.)?

As Glenn mentioned, the check plate shims on the rebound piston might be cupped. If they aren't too bad some folks simply flip them over.
If the fork tubes have front to back play it's time for new bushings.

Thoughts on going from 5 wt. to 2 1/2 wt. oil ?

When it's warm I've noticed little overall performance difference between different weight oils (ATF @ 35cSt to hydraulic oil @ 10cSt). In cold weather oils with a high pour point result in a brutally stiff ride. If you change oil viscosity you'll end up adjusting the clickers to compensate for a different oil, but high speed operation doesn't noticibly change.

Tools that are worth buying instead of improvising ?

For a mid level overhaul, fork tube bushings (leave the damper rod bushing alone for now), seals, piston bands and o-rings, a seal driver and a way to set oil level is all you'll need.

[KTMLew]

Originally Posted by Dave

Get the earlier EXC kit for your 43s - the later kit is for 48mm tubes.

For a mid level overhaul, fork tube bushings (leave the damper rod bushing alone for now), seals, piston bands and o-rings, a seal driver and a way to set oil level is all you'll need.

You want the 00-01 kit. All the parts he recommended above come with the Pivotworks kits!!!

Try this place for a good seal driver.

http://www.pitposse.com/suspension.html

I have used PVC as a driver but a real driver works much better. I don't really care for the oil level guages that use a syringe. You are better of buying a Mity-Vac for brake bleeding & a 12" piece of steel tubing. Then you have a multi-purpose tool!

[skid jackson]

Any idea what the name of the shop in NY is?? There is a joint called HY Gear suspension that does alot of sled work and bikes. I've delt with them for sled stuff. Seemed to know what they were doing.

[Brian VT]

Originally Posted by skid jackson

Any idea what the name of the shop in NY is??

Nope. I think he said it was near Albany ?
Thanks for all the advice guys.
Any downfalls to the universal seal driver as opposed to the dedicated 43mm ?

[Brian VT]

I decided to dig in today. I didn't get too far.
The manual says to pull the spring down and use a # 20 spanner. I don't have a 20mm so I tried a 13/16" (20.64 mm) but it was too thick so I ground it down. Wrong size.
I'm guessing it takes a 21mm ? I'll buy one tomorrow. I assume I'll have to grind that one thinner too. If that doesn't do it I'll be grinding down my adjustable wrench. lol

[KTMLew]

Takes a 22mm wrench.